A METHOD TO MAKE BICOMPONENT FIBERS AND ARTICLES COMPRISING THE SAME
The disclosure generally relates to bicomponent fibers, and more particularly, methods to make bicomponent fibers and articles comprising them, wherein a first extruded component has a moisture level less than a second extruded component. The bicomponent fibers may comprise polyesters and are useful in articles such as carpets and fabrics.
1 . A method to make bicomponent fibers comprising:
a) extruding a first and second component on a spinning machine capable of producing two or more independent melt streams;
b) combining the melt streams in a spinneret suited for making bicomponent fibers;
c) quenching in air the bicomponent fibers produced in step (b);
d) drawing and heat setting the quenched bicomponent fibers; and
e) winding up the bicomponent fibers in step (d) by any suitable means;
wherein the first extruded component has a moisture level less than the second extruded component.
2 . The method according to claim 1 , wherein the first and second component is independently selected from the group consisting of: polyesters, nylons, and combinations thereof.
3 . The method according to any one of claims 1-2 , wherein the first and second component is a polyester independently selected from the group consisting of: poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and copolymers thereof and the second component is a polyester selected from the group consisting of: poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and copolymers thereof.
4 . The method according to any one of claims 1-3 , wherein the first component is poly(ethylene terephthalate) and the second component is poly(trimethylene terephthalate).
5 . The method according to any one of claims 1-4 , wherein the first component has moisture level in a range from about 10% to about 20% and the second component has a moisture level in a range from about 90% to about 80.
6 . The method according to any one of claims 1-5 , wherein the first component has a moisture level of about 50 ppm or less and the second component has a moisture level greater than about 50 ppm.
7 . The method according to claim 1 , wherein a stretch measurement of the bicomponent fibers produced in step (e) increased in a range from about 10% to about 85% as compared to bicomponent fibers made by steps (a) to (e) wherein the first extruded component did not have a moisture level less than the moisture level of the second extruded component.
8 . The method according to claim 7 , wherein the stretch measurement increase is selected from the group consisting of: 12%, 17%, and 40%.
9 . The method according to claim 1 , wherein the first and second components of the bicomponent fiber are present in a weight percent ratio ranging from 20:80 to 80:20.
10 . The method according to claim 1 , wherein the bicomponent fiber is in a configuration selected from the group consisting of: side-by-side, eccentric sheath core configuration, and trilobal.
11 . The method according to claim 11 , wherein the crimp contraction after heating of the bicomponent fiber, of step (e), is in a range from about 10% to about 85% as determined according to the Crimp Contraction Method.
12 . The method of claim 1 , wherein an extruder temperature of one of the components in step (a) is in a range from about 240° C. to about 320° C.
13 . The method according to claim 12 , wherein an extruder temperature of one of the two extruded components in step (a) is selected from the group consisting of: 260° C., 270° C., 280° C., 290° C., 300° C., 310° C., and 320° C.
14 . An article of clothing comprising bicomponent fibers made by the method of claim 1 .
15 . A fabric comprising bicomponent fibers made by the method of claim 1 .
16 . A fully drawn yarn comprising bicomponent fibers made by the method of claim 1 .
17 . A partially oriented yarn comprising bicomponent fibers made by the method of claim 1 .
18 . A staple fiber comprising bicomponent fibers made by the method of claim 1 .
19 . A carpet whose face fiber comprises bicomponent fibers made from the method of claim 1 .
20 . The carpet of claim 19 , wherein the bicomponent fiber is in a configuration selected from the group consisting of: side-by-side, eccentric sheath core configuration, and trilobal.
21 . The carpet of claim 20 , wherein the face fiber further comprises at least one additional fiber selected from the group consisting of: bulked continuous filament, synthetic staple fiber, and natural fiber.
22 . The carpet of claim 21 , wherein the at least one additional fiber is bulked continuous filament, and the bulked continuous filament comprises nylon, polypropylene, or polyester.
23 . The carpet of claim 21 , wherein the at least one additional fiber is synthetic staple fiber, and the synthetic staple fiber comprises nylon or polyester.
24 . The carpet of claim 21 , wherein the at least one additional fiber is natural fiber, and the natural fiber comprises wool, silk, or cotton.
25 . A non-woven fiber comprising bicomponent fibers made by the method of claim 1 .
26 . A non-woven fabric comprising bicomponent fibers made by the method of claim 1 .